Device, System and Method for Improving Efficiency and Preventing Degradation of Energy Storage Devices

ABSTRACT

Disclosed herein is a method and related device for improving energy performance and substantially preventing degradation of a chemical-to-electrical energy conversion process of an energy storage device ( 10 ), comprising the steps of: mechanically exciting chemical reaction products within the energy storage device ( 10 ) at energy levels proximate which covalent bonds with a matrix ( 51 ) of the energy storage device ( 10 ) would form absent excitation, thereby substantially maintaining ionic bonding between the chemical reaction products and the matrix ( 51 ) and substantially preventing the chemical reaction products from covalently bonding with the matrix ( 51 ); and introducing the mechanical excitations into the energy storage device ( 10 ) via an active material ( 31 ) mechanically-responsive to electromagnetic signals, in response to an electromagnetic signal.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of application U.S. Ser. No.10/543,296 filed Jul. 26, 2005, now U.S. Pat. No. 7,592,094 issued Sep.22, 2009. Said U.S. Ser. No. 10/543,296 is in turn a US national stageapplication of PCT/US04/02663 filed Jan. 30, 2004, now expired. SaidPCT/US04/02663 in turn claims benefit of U.S. 60/319,921 filed Feb. 3,2003, now expired. All of the foregoing are hereby incorporated byreference.

FIELD OF THE INVENTION

This invention pertains generally to improving the electricalperformance of energy storage devices, and in particular to improvingthe efficiency and preventing electrode degradation of an energy storagedevice.

BACKGROUND OF THE INVENTION

The lead (Pb) and lead dioxide (PbO₂) material used for lead-acidbattery electrodes (hereinafter the “matrix”) are very porous materials.This porosity allows the electrolyte completely to penetrate the matrixand chemically react within it. This in turn increases thecurrent-carrying capacity of the battery. Without these pores thebattery's load carrying ability would suffer greatly. Unfortunately,nothing is gained without giving something up. FIG. 1 illustrates a“like-new, porous electrode” which has not been in contact withelectrolyte. FIG. 2 illustrates a similar electrode after six months ofuse. While lead-acid batteries will be used here for illustrativepurposes, analogous considerations apply generally to otherchemical-to-electrical energy storage devices employing alternativeelectrode and electrolytic materials.

When a lead-acid battery discharges, PbSO₄'s form within the pores andon the surface of the matrix. The formation of PbSO₄'s on the surface ofthe matrix does not present a real problem; these sulfates (SO₄'s) gointo solution easily during the charge cycle. It is the formation ofPbSO₄'s within the matrix that deteriorates the battery's capacity overtime. After several charge and discharge cycles these PbSO₄'s build upwithin the pores. The strength of the bonds created between Pb and SO₄have several different levels. The longer these two molecules remain incontact the stronger the bonds become. If every SO₄ is not driven backinto solution during the charging process, the remaining PbSO₄ bondsgrow stronger and stronger, dropping to lower and lower covalent energylevels. At this point the amount of time and current required to breakthese bonds will have to be increased, and the collateral damage to thebattery resulting from such removal increases significantly.

Eventually these stubborn PbSO₄ formations will crystallize (sulfation)and block passage of the electrolyte through the matrix. Sulfationlowers the current-carrying capacity and over time limits the energystorage capacity of the battery. It also diminishes the life of thebattery and can cause structural damage. It is this limitation thatrequires users to apply voltages much higher than that of the batteryitself in order to recharge it, and that results in batteries being madelarger then they would otherwise need to be to store and deliver a givenquantity of energy.

The sulfate ion has several different energy-bonding states or energylevels. Over time, there is a transition—a drop in energy level—from aless-stable ionic bond to a very-stable covalent bond. These moleculesstack up like shingles to cover the surface of and the porous regionsthroughout the matrix. The effect is like painting the battery platewith a resistive coating. The useful life of a lead-acid battery isdictated by the ability to break up these deposits.

Early attempts to eliminate lead-acid sulfation began with equalizationor “over charging.” This process was successful at removing most of thedeposits, but at a very high cost to the battery life span, due to theerosion of the positive plate grid structure. The process, being highlyexothermic, results in heat generation, plate warpage and mechanicalstress on cell components. There are numerous examples of battery cellsexploding as a result of equalization. Later a safer electronic chargingprocess was developed. This improved technique is still unable to removethe oldest and most stable sulfate deposits from the plates. Thisprocess still relies on large voltages, and therefore currents, when thecharge is applied. Thus, this process also results in the adversefactors mentioned above, and wastes energy. In addition, this process ofcharging is very time-consuming.

Some efforts to address sulfation focus on improved chemicalconstituents, for example, U.S. Pat. No. 5,945,236 for an electrolyteadditive and U.S. Pat. No. 6,458,489 which alters the concentration ofH₂SO₄ in a lead acid battery

Many attempts have been made to use large pulsating currents to reducesulfation and similar deposits. For example:

U.S. Pat. No. 5,491,399 discloses “a fast rise time current pulse forapplication to a battery” (abstract), which, based on FIGS. 2 and 3,appears to be on the order of a few μsec, which translates to a 500 KHzfrequency. This—like virtually all the prior art—is used for “removingthe lead sulfate deposits from the battery plates” (column 1, lines37-38).

U.S. Pat. No. 5,525,892 discloses using “a positive voltage pulse train(characterized by a fast rise time spike followed by a non-uniformhump-shaped trail-off) that is combined with a DC charging currentoutput by the charger” (abstract). “[T]he shape of the trail-off of eachpulse is not uniform from pulse to pulse in the pulse train. Thisfluctuation in the shape characteristics of the pulses within the pulsetrain is believed to result in improved sulfate deposit removal” (column1, lines 47-48). “The rise time 208 for the spike portions 204 of thepulses 202 generated by the pulsed battery rejuvenator 10 isapproximately four to eight microseconds per pulse” (column 3, lines55-58), translating to a frequency from about 125 to 250 KHz.

U.S. Pat. No. 5,677,612 discloses that a “battery desulfator operates bytaking a small amount of energy from the battery 124, which passesthrough the oscillator or multivibrator 125, which in turn transformsthe battery DC voltage into high frequency pulses which are fed backinto the battery 124” (column 2, lines 17-21). While no frequencies arespecifically disclosed, it is noted that the “process continues at arate of several thousand times per second” (column 3, lines 25-26).

U.S. Pat. No. 5,808,447 discloses “pulse charging [which] charges arechargeable battery by repeatedly alternating periods of charging andsuspension of charging” (column 2, lines 30-32). The “400 msec” intervalmentioned in column 6, line 6 and elsewhere is suggestive of anapproximate 2.5 KHz frequency.

U.S. Pat. No. 6,130,522 discloses “connecting a current source deviceacross the positive and negative terminals of the battery and applying aperiodic pulse to the device so as to apply a pulsed current across thebattery terminals without applying a voltage pulse” (abstract). “Thepulse frequency is selectable over a wide range but preferably isgreater than the frequency of the base charger current so that itpreferably ranges from 60 Hz to 100,000 Hz” (column 4, lines 55-58).

U.S. Pat. No. 5,891,590 discloses “[a] device and method for reducingcrystal formations, which have a range of resonant frequencies, onelectrode plates of an electrical battery . . . [using] a train ofdirect current pulses at a frequency within the range of resonantfrequencies . . . ” (abstract). It appears that the “resonantfrequencies” referred to something other than chemical bondingresonances, because “[t]he frequency is selected to fall within a rangeof frequencies that is believed to correspond to the range of resonantfrequencies of the lead sulfate crystals. Preferably, the range is inthe order of about 10 KHz to 32 KHz and more preferably in a range ofabout 20 KHz to 32 KHz” (column 4, lines 5-9). The resonant frequency ofchemical bonds connecting Pb to SO₄ in PbSO₄ is in fact on the order of3.26 MHz at the lowest covalent bonding energy—over 100 times as high asthe frequencies discussed here—so it is clear that these chemical bondsare not at all under consideration in U.S. Pat. No. 5,891,590.

Among many other problems, all of U.S. Pat. Nos. 5,491,399; 5,525,892;5,677,612; 5,808,447; 6,130,522; and 5,891,590 employ frequencies in thesub-500 KHz range, and such low frequencies are insufficient to get atthe root cause of lead-acid battery sulfation—namely—the covalentchemical bonds which form between Pb to SO₄ in PbSO₄, or to addresssimilar plating phenomena in other types of batteries.

U.S. Pat. No. 5,276,393 discloses “[a] solar powered battery reclaimingand charging circuit . . . having a high frequency section . . . andoutput coupled by a close coupled RF transformer to the batteryconnected output section. The transformer has a secondary windingproducing a current-voltage full wave output sharply defined through atwo diode rectifying circuit to a multi-frequency 10 KHz to 100 KHzpulse output. The sharp pulse outputs with RF content in the 2-10megahertz frequency range have specific frequencies equal to naturalresonant frequencies of the specific electrolytes used in respectivebatteries. These resulting high frequency RF output signals in eachpulse envelope structure are capable of reclaiming, maintaining andcharging batteries that possess a liquid electrolyte or jell electrolyteand are beneficial to dry cell batteries as well in extending batterylife” (abstract, see also column 1, lines 48-68). This patent thusfocuses on the resonant frequencies of the “specific electrolytes” underconsideration.

U.S. Pat. No. 6,184,650 observes that “[i]t is possible to reverse[i.e., remove, not prevent] the build-up of sulfur crystals on thecollectors (plates) of a lead-acid type storage battery. By ‘hitting’these plates with electrical pulses which produce energy at 3.26 MHz.,which is the resonant frequency of a sulfur crystal, the bond is broken,allowing the molecules to dissolve back into the electrolyte solutionfrom which they first came” (column 1, lines 8-15). It is further statedthat “[t]his invention is capable of reversing the build-up ofcrystallized sulfur on the ‘plates’ of a lead-acid storage battery,thereby improving the charge/discharge characteristics of a battery inwhich such formations have occurred. It accomplishes this process byrapidly turning the charger on and off (rise time=200-500 nsec.) and bygenerating pulses (1 Amp amplitude) during the ‘float’ charge cycle”(column 1, lines 25-32).

These two patents, U.S. Pat. Nos. 5,276,393 and 6,184,650, provide amore satisfactory frequency range for addressing sulfation. However,they still rely on pulsed, electrical stimulation of the battery, whichitself wastes energy and damages the battery. This process ofperiodically sending large voltage spikes into the battery may havedesirable short-term effects, but the long-term effects are detrimentalto the battery performance and should be avoided. A sharp electricalpulse at such high frequency to remove sulfate deposits which havealready formed is akin to attacking the matrix with a jackhammer: thedeposits may be removed, but the matrix itself is also damaged in theprocess.

Although an electrical pulse may contain frequency components requiredto resonate the crystal's structure, these pulses also contain otherfrequency components which serve no useful purpose in the minimizationof sulfation and therefore improved battery performance. These extrafrequency components contain energy and this energy is being wastedunnecessarily. The process of injecting pulsed electrical energy into acovalent bond to create a mechanical response is highly inefficient.This electromagnetic-to-mechanical conversion process is similar to thatof a microwave oven. The radiation in a microwave oven is used tomechanically excite the water molecule bonds present in the material. Itis well known that the energy required to heat a glass of water fromroom temperature to the boiling point is much greater than the energythe glass of water actually received. This excess energy is wasted andif there were a more efficient way to inject the energy into themechanical type bonds of water the microwave would be much moreefficient device.

These patents which rely on electrical stimulation are not concernedwith this wasted energy. In addition, the large voltages containedwithin the pulse are applied across water molecules and throughelectrolysis, so more gassing is likely. This is also a form of wastedenergy. Although some gassing is essential to battery performance, toomuch gassing is detrimental to battery life. Therefore, in achieving itsobjective, all of these patents which employ electrical stimulation toremove sulfates after they are already formed not only waste valuableenergy but also degrade the life of the storage device. If a methodcould be found that eliminates the need for these high voltages andcurrents, the wasted energy and the degradation of a storage devicecould be eliminated. In other words, the performance characteristics ofan energy storage device can be improved. Since these patents are notconcerned with the amount of energy used to achieve its goal, they shifttheir focus from energy storage to sulfate minimization and haveeffectively defeated the underlying foundation of a battery—efficientenergy storage.

U.S. Pat. No. 5,872,443 discloses “[a]n electronic method . . . wherebythe applied electromotive force optimizes the electrokinetic behavior ofcharged particles to match closely the natural electrical response andphysical structure of the system. The method shapes the electromotiveforce's amplitude and frequency to normalize the relative interactionsbetween the charged particles and the physical structure.” Whileinteresting as general background, the application of an electromotiveforce in this patent still poses the same problems as in theaforementioned patents.

A fair number of other patents take a mechanical, rather than electricalapproach. For example:

U.S. Pat. Nos. 6,299,998 and 6,458,480 disclose batteries with movableanodes, and U.S. Pat. No. 4,587,182 discloses the use of a “compressiveload on the anode which inhibits the formation of a porous deposit ofexterior, irregularly oriented, amalgamated lithium grains on the anode”(abstract).

U.S. Pat. No. 3,923,550 discloses that “to avoid dendrite formation whencharging an alkaline accumulator battery cell having a zinc anode . . .either the separator or the anode is subjected to a vibratory movementduring the charging process” (abstract). “The vibratory movement issuitable carried out with a frequency of 0.01-1000 Hz, preferably 1-500Hz” (column 2, lines 19-20).

U.S. Pat. No. 5,352,544 discloses “a method for increasing the ionicconductivity of solid polymer electrolytes which comprises mechanicallyexciting the units which comprise the polymer electrolytes [and] a . . .solid state battery having a solid polymer electrolyte and means formechanically exciting the polymer electrolyte” (column 2, lines 14-22).In particular, this patent employs “mechanical excitation over afrequency range of 40-400 KHz” (column 3, lines 27-28 and elsewhere).

U.S. Pat. No. 5,932,991 discloses “enhancing the charging of a batteryby exposing the battery to acoustic excitation while the battery isbeing charged” (abstract) and specifically the use of a 20 KHz.frequency (column 3, line 52, and several other places).

U.S. Pat. No. 6,060,198 employs a transducer. “The ultrasonic frequencyto be selected and its intensity are functions of the structuralcharacteristics of the entire battery. Usually the frequency range willbe between about 20 KHz and about 120 KHz. The required wattage issurprisingly low. Typically between about 10 to about 20 watts output ofvibrational energy will be sufficient.” (column 5, lines 31-36). This isa good example of mechanically-based approaches where the frequencyand/or pulse rise time is determined by reference to the physical,structural elements of the battery.

U.S. Pat. No. 5,963,008, in a similar vein, discloses that“[e]lectroacoustic battery sonication rehabilitates a battery bydecreasing metallic shorting across battery elements through sonication.Sonication may be produced by application of an electrical signal[damaging to the battery as earlier discussed] of selected frequency tothe terminals of a battery, thereby establishing a resonant conditionwithin the battery. Alternately, sonication may be provided bytransducers placed within a battery and receiving a drive signal ofselected frequency to establish a resonant condition within the battery”(abstract). More specifically, it is disclosed that “an appropriateresonant frequency for sonication in a lead acid battery may beapproximated under these calculations and, in general, a 200-300kilohertz frequency is productive. A lower frequency may work to somedegree, but will be of lesser effect. Higher frequencies, however,produce vibration of smaller portions of a given body. The nature andshape of the battery elements to be vibrated drives frequency selectionto the range suggested herein. A typical lead acid battery grid consistsof squares, or a similar shape, of approximately 0.01 m. Thischaracteristic of typical lead acid batteries provided a basis forselecting a 0.01 m wavelength in the above calculations. Other batteryconfigurations would likely exhibit different resonant characteristicsand would possibly require different sonication signal frequencies”(column 4, lines 37-51).

The “above calculations” for selecting the “sonication” frequency areset forth in the formulae in column 4, lines 25-34. The frequencies areselected based on the speed of sound in the electrode grid and the sizeof the typical grid elements, i.e., squares, according toFREQUENCY=VELOCITY OF SOUND IN THE GRID/SIZE OF GRID ELEMENT. Accordingto this approach, using the unbounded lead calculation, one would notemploy a frequency as high as 1 MHz unless and until the grid elementsize reached approximately 2.5 mm, which is very small.

U.S. Pat. No. 5,614,332 is very similar to U.S. Pat. No. 5,963,008 (andU.S. Pat. No. 6,060,198) in its underlying theory of how to select anappropriate frequency for mechanical stimulation. It too discloses abattery in which “electrodes are connected to a charging or dischargingcircuit and at least one electrode is mechanically manipulated duringthe charging or discharging” (abstract). “The preferred frequency is onthe order of 50 KHz for a battery electrode of characteristic length 10cm . . . The frequency scales inversely with the battery electrode size.Thus, a 100 cm long battery electrode would require a 5 KHz minimumfrequency” (column 6, lines 9-12). Although “FIG. 13 shows an ultrasonictransducer 132 . . . which can operate at frequencies as high as 2 MHz,”which is still substantially less than, say, the 3.26 MHz frequency ofPbSO₄, it is clear that such a high frequency—based on the inversefrequency scaling disclosure of this patent later given more precisedefinition in U.S. Pat. No. 5,963,008—would be employed for a (50KHz/2000 KHz)×10 cm=2.5 mm long battery electrode, that is, for amicro-battery cell.

This is the same sort of result reached in U.S. Pat. No. 5,963,008,namely, that high frequencies in the MHz. range would be employed onlyif one was considering very small electrodes or electrode elements,i.e., squares, in the range of millimeters and smaller. As such, whilethe availability of frequencies “as high as 2 MHz” are noted in passing,U.S. Pat. No. 5,614,332 focuses on ways to “plastically deform” theelectrode (see independent claims), and—in the same manner as U.S. Pat.No. 5,963,008—teaches away from the use of higher frequencies unless oneis dealing with very small (millimeter-sized) electrodes or electrodesquares.

Mechanical stimulation is much preferred to electrical stimulation,because it avoids many of the problems mentioned above with respect towasted energy and added degradation. However, all of the prior art thatinvolves mechanical stimulation focuses on the physical structures ofthe battery, and not on the chemistry which bonds the chemical reactionproducts to the electrodes. They all teach that where mechanicalstimulation is concerned, the pertinent data for selecting frequenciesare such things as the speed of sound in the medium being vibrated, andthe physical size of the battery structure that one is looking tostimulate. Thus, as taught in column 6, lines 9-10 of U.S. Pat. No.5,614,332, “[t]he frequency scales inversely with the battery electrodesize.” And, as taught starting at column 5, line 31 of U.S. Pat. No.6,060,198, “[t]he ultrasonic frequency to be selected and its intensityare functions of the structural characteristics of the entire battery.”And, as clearly taught in U.S. Pat. No. 5,963,008 at column 4, lines42-44, “[t]he nature and shape of the of the battery elements to bevibrated drives frequency selection.”

There is no suggestion whatsoever about introducing mechanicalexcitations at energy levels at which covalent bonds are formed with theelectrodes, and indeed, all of the patents which employ sound waves(mechanical stimulation) teach directly away from this by suggestingthat frequency is determined based on the physical structure of thebattery, and that higher frequencies are of interest only when smallstructural features are being considered. That is, these patents arewholly focused on manipulating the electrode or the battery structure—toremove not prevent sulfation and like effects in the first place—and noton preventing undesired bonding of chemical reaction products with theelectrode.

SUMMARY OF THE INVENTION

Disclosed herein is a method and related device for improving energyperformance and substantially preventing degradation of achemical-to-electrical energy conversion process of an energy storagedevice, comprising the steps of: mechanically exciting chemical reactionproducts within the energy storage device at energy levels proximatewhich covalent bonds with a matrix of the energy storage device wouldform absent excitation, thereby substantially maintaining ionic bondingbetween the chemical reaction products and the matrix and substantiallypreventing the chemical reaction products from covalently bonding withthe matrix; and introducing the mechanical excitations into the energystorage device via an active material mechanically-responsive toelectromagnetic signals, in response to an electromagnetic signal;whereby: degradation is substantially prevented by substantiallypreventing the covalent bonds from forming and by exciting the energystorage device mechanically rather than via degrading electricalexcitation; and energy performance is improved by requiring loweramounts of energy for exciting the chemical reaction products via saidactive material than would be required to similarly excite the chemicalreaction products without said active material, and by substantiallypreventing the covalent bonds from forming and causing degradation.

Further disclosed is a method and device with corresponding specialtechnical features for improving energy performance and substantiallypreventing degradation of a chemical-to-electrical energy conversionprocess of an energy storage device, comprising the steps of:mechanically exciting an energy storage device at frequencies proximateresonant frequencies at which covalent bonds between chemical reactionproducts within and a matrix of the energy storage device would formabsent excitation; and introducing the mechanical excitations into theenergy storage device via an active material mechanically-responsive toelectromagnetic signals, in response to an electromagnetic signal.

BRIEF DESCRIPTION OF DRAWINGS

The features of the invention believed to be novel are set forth in theappended claims. The invention, however, together with further objectsand advantages thereof, may best be understood by reference to thefollowing description taken in conjunction with the accompanyingdrawing(s) summarized below.

FIG. 1 is a photograph which illustrates a microscopic section of anelectrode which has not been in contact with electrolyte.

FIG. 2 is a photograph which illustrates a microscopic section of asimilar electrode after six months of use.

FIG. 3 is a schematic perspective view which illustrates lead zirconatetitanate (PZT) film substrate housed within a material which will notreact chemically within the cell, in one embodiment of the invention.

FIG. 4 is a graph illustrating a design approach for the PZT frequencyoscillations during charge and discharge, when employed in variousembodiments of the invention.

FIG. 5, not to scale, is a perspective view illustrating a smallsectional cutaway view of an active battery grid in one embodiment ofthe invention, in a completely discharged state.

FIG. 6 is a circuit diagram illustrating a charge and discharge modelfor an energy storage device in various embodiments of the invention.

FIG. 7 is a circuit diagram illustrating a discharge model for an energystorage device in various embodiments of the invention.

FIG. 8 is a circuit diagram illustrating a charge model for an energystorage device in various embodiments of the invention.

FIG. 9 is a top plan view which illustrates an exploded view of anactive grid element, as well as the sulfate or similar “clouds” whichform about this element.

FIG. 10 illustrates an AGT energy end product, e.g., battery, in variousembodiments.

DETAILED DESCRIPTION

This disclosure will demonstrate a method and/or a process that can beused within an energy storage device 10 (e. g., battery, or any otherenergy storage device 10 using a matrix 51 with an electrolyte) toprevent sulfate deposits or their counterparts from reaching a levelthat will degrade the device. In doing so, several benefits will becomeapparent.

However, this disclosure is not limited to energy storage devices. Thedisclosures herein will work to assist several types of reversiblechemical reactions. A solar cell can benefit by better preparing thecell to transfer energy. And, in general, this disclosure can be used tohelp with any chemical reaction for which its constituents “plate out”thus impeding the reverse reaction. It is also the purpose of thisdisclosure to demonstrate, by applying this process to a technologyalready in place, the present limitations that will be eliminated.Energy storage devices, such as the lead-acid batteries used forillustration, but also nickel-cadmium; nickel-metal-hydride,lithium-ion, lithium-polymer, high temperature sodium-sulfur batteriesand certain types of fuel cells, all will benefit from the use of thisprocess.

Current methods of charging an energy storage device 10 are timeconsuming and inefficient. The time required completely to charge alead-acid battery, for example, is on the order of hours. The energy putinto a battery during this charge is always much greater than itreturns. There are several factors that cause this to happen and themajor ones will be discussed herein. Many attempts by the batteryindustry have minimized these shortcomings but have failed to eliminatethem. The Active-Grid Technology (AGT) disclosed herein, eliminates allof them, not by using a chemically active substance, but—in a primaryembodiment—by using an active electrode, or “smart” electrode, that iscontrollable. In this primary embodiment, the active electrodes vibrateat a very low level (amplitude) during both the discharge and chargecycles. During the discharge phase the bonds of the chemical reactionprecipitates—lead sulfate (PbSO₄) in the case of a lead-acid battery—arekept unstable, i.e., at their highest energy state, thus preventing themfrom stabilizing and forming stronger bonds. Then, when the charge isapplied, very little energy is required to send the excited sulfate ionsback into solution. Currently-used techniques such as those describedabove are focused on re-conditioning a battery after degradation hasalready occurred. AGT is focused on preventing this degradation fromhappening in the first place. By preventing these detrimental bonds fromforming in the first place, the energy required to break them in thereverse chemical reaction is not required, thereby substantiallyincreasing the efficiency of the energy conversion process and avoidingdamage to the battery structure. In addition, much of the prior art usesa process referred to as recombination. This process recombines gasesproduced within an energy storage device 10, thereby eliminating thedetrimental effects associated with gassing. AGT is a process that willsharply reduce gassing before it ever occurs.

Again, lead-acid battery will be used for illustrative purposes. In alead-acid battery, the matrix 51 is lead (Pb) or lead dioxide (PbO₂) andthe electrolyte is sulfuric acid (H₂SO₄). During the discharge reaction,the chemical reaction products, particularly sulfate (SO₄) ions, willtransfer electrons with the lead ions thus establishing an ionic bond.While the sulfates remains in the vicinity of the matrix 51, these bondswill drop to successively lower energy levels and covalent bonds willthen form which ultimately degrade the energy conversion process. Theresulting precipitate is PbSO₄. As this covalent relationshipstrengthens over time, going to successively lower energy states,sulfation (crystallization) will occur which will degrade the batteryand eventually destroy it. AGT excites the chemical reaction productswithin the energy storage device 10 at energy levels proximate whichcovalent bonds with a matrix 51 of the energy storage device 10 wouldform absent excitation, thereby substantially maintaining ionic bondingbetween the chemical reaction products and the matrix 51 andsubstantially preventing the chemical reaction products from covalentlybonding with the matrix 51. In the special case of a lead-acid battery,this means that AGT prevents sulfation and less energy is required toreverse the chemical reaction.

For a NiMH battery, the matrix 51 is NiO and MH, the electrolyte is KOH,and the goal is to prevent the chemical reaction precipitate Ni(OH)₂from forming detrimental covalent bonds thus preventing crystallizationand reducing the amount of energy required to reverse the chemicalreaction. In this case, AGT excites the chemical reaction products (OH)₂at the energy levels proximate which the covalent bonds between the Niand (OH)₂ would otherwise form absent excitation, thereby substantiallypreventing the chemical reaction products from forming detrimentalcovalent bonds with the matrix 51.

For a NiCd battery, the matrix 51 is Cd and NiO, the electrolyte is KOH,and the goal is to prevent the chemical reaction precipitates Cd(OH)₂and Ni(OH)₂ from forming detrimental covalent bonds thus preventingcrystallization and reducing the amount of energy required to reversethe chemical reaction. In this case, AGT excites the chemical reactionproducts (OH)₂ at the energy levels proximate which the covalent bondsbetween the Ni and (OH)₂, and Cd and (OH)₂, would otherwise exist absentexcitation, thereby substantially preventing the chemical reactionproducts from forming detrimental covalent bonds with the matrix 51.

For a Li-Ion battery, the matrix 51 is Li and some other type of alloy(X), and the goal is to prevent the chemical reaction product LiXO₂ fromforming detrimental covalent bonds thus preventing crystallization andreducing the amount of energy required to reverse the chemical reaction.In this case, AGT excites the chemical reaction products XO₂ at energylevels proximate which covalent bonds between the Li and XO₂ wouldotherwise exist absent excitation, thereby substantially preventing thechemical reaction products from forming detrimental covalent bonds withthe matrix 51.

Thus, it is to be understood that the term “matrix” as employed hereinrefers to whatever electrode material may be employed in a given type ofbattery, whether this is lead for a lead-acid battery, Ni for a NiMhbattery, Cd for a NiCd battery, Li for a Li-Ion battery, or Ag and Znfor a AgZn battery, for example. This disclosure applies to similarbatteries and their materials which are not expressly enumerated here,and as may be developed in the future. It is also recognized by thisdisclosure that the chemical reactions illustrated are only one of manyof the reactions taking place within the energy storage device 10. Thisdisclosure is concentrated on the majority reactions taking place withinthe energy storage device 10—that is, on the reactions which drive theproduction of energy during discharge, and on the reactions needed toreconstitute the electrolyte during recharge. Similarly, it is to beunderstood that the “chemical reaction products” refer generally to thefree atoms or molecules that break free from the electrolyte duringdischarge and which in turn form ionic and covalent bonds with themolecules or atoms of the matrix 51 in which the covalent bonds tend todegrade the battery's performance over time and increases the energyrequired to reverse the chemical reaction. For a lead acid battery, theelectrolyte is H₂SO₄, and one of the chemical reaction product is SO₄,which ionically bonds with Pb to form PbSO₄ precipitate, and it is thesubsequent formation of covalent bonds between the Pb and the SO₄ whichleads to the degradation of the battery performance and the excessenergy required to reverse the chemical reaction and so is to be avertedwith AGT.

For a NiMh battery, the electrolyte is KOH, and the chemical reactionproduct is OH, which ionically bonds with the Ni to form Ni(OH)₂precipitate, and it is the subsequent formation of covalent bonds whichleads to the degradation of the battery performance and excess energyrequired to reverse the chemical reaction and so is to be averted withAGT. For a NiCd battery, the electrolyte is KOH, and the chemicalreaction product is OH, which ionically bonds with the Ni and CD to formNi(OH)₂ and Cd(OH)₂ precipitate and it is the subsequent formation ofcovalent bonds which leads to the degradation of the battery'sperformance and excess energy required to reverse the chemical reactionand so is to be averted with AGT. Again, this applies to similarbatteries and their materials which are not expressly enumerated here,and as may be developed in the future.

Active Grid Technology (AGT) employs devices and methods that do notrely on applying damaging large voltages and/or currents across thebattery potential, as is the case with the various electricalstimulation patents discussed earlier. It keeps the chemical reactionproducts, e.g., SO₄'s, stirred up during the discharge so that covalentbonds never form in the first place. If a SO₄ ion tries to go to a lowerstate so as to form a covalent bond with the energy storage devicematrix 51, AGT will prevent it from doing so. Therefore smaller voltagesand currents are required to recharge a battery, and the “jackhammer” ofquick rise time currents is never needed.

To prevent the formation of sulfate bonds, the energy level of the SO₄molecule must be maintained at a point where the electrons in the outervalence band are excited to the next higher band, leaving the atomsunbound with respect to one another. Thus it is necessary to excitethese bonds, which will enable the excited molecule to move to a higherstate. This process is administered during the discharge phase to keepsubstantially all bonds in the uppermost or highest excited state. Then,and only then, can the sulfate molecule be converted to a free ion insolution. When the reverse current (re-charge) is applied, it will givethese elevated bonds the excess energy required to part from the matrix51 and return to the electrolyte. This approach eliminates sulfation inthe lead-acid example, and generally substantially maintains ionicbonding between the chemical reaction products and the matrix 51 andsubstantially prevents the chemical reaction products from covalentlybonding with the matrix 51.

AGT elevates the bonds that form in an energy storage device 10 while itis being used as an energy source (discharge). In other words, as thestorage device performs its intended function, AGT will not allow thesulfation to occur, and more generally will not allow the chemicalreaction products to form covalent bonds with the matrix 51. AGTelevates these bonds by applying a low level disturbance proximate thefrequencies for which the covalent bonds want to exist (lower energystates). This excitation aids in preventing sulfate ionic bonds (andmore generally the bonds between the chemical reaction products and thematrix 51) from reaching these lower energy covalent states. Thus whenthe storage device is charged, only very small voltages and currents areneeded to drive the chemical reaction products back into theelectrolyte. AGT eliminates sulfation (and similar plating in otherbatteries) and its detrimental effects noted above. In doing so, AGT haspaved the way to an effective and efficient energy storage device 10.Instead of using one form of energy to charge a storage device, AGT hasdivided into separate entities the energy used to charge a battery.Mechanical, rather than electrical energy is used to elevate the bondscreated during the discharge phase. Since these bonds remainsubstantially elevated the lower energy covalent bonds are substantiallyprevented from forming. During the charge phase, both electrical andmechanical energy are used. In preferred embodiments, electrical energyis of course used to recharge the battery in the usual manner, andmechanical energy facilitates the driving of the chemical reactionproducts back into the electrolyte. This line of thinking shifts theparadigm away from that of sulfation elimination to that of sulfationprevention, thereby achieving storage device performance improvement.AGT does not waste energy, and does not accept the associateddegradation; it uses that excess energy for its intended purpose—itstores it and delivers it.

A lead-acid battery does not actually suffer from memory, but as thebattery ages it acts as though it does. When the PbSO₄'s grow(crystallize) they cause stress on the matrix 51 and portions of thematrix 51 will fall to the bottom of the battery (shedding). Sheddinglowers the capacity of the battery, diminishes the life of the batteryand can cause shorted cells. When a reverse current is applied (charge)a majority of the SO₄'s are be driven back into solution. If the chargeis not sufficient it will not be able to overcome the stronger bondsformed within the matrix 51. Sulfation and shedding are very limiting inbattery design, and manufacturers have been trying to minimize theseeffects for decades. If these effects are eliminated, the battery couldbe made much smaller and its energy storage capacity can be maintainedover time, substantially without loss as the battery ages. Batterymanufactures presently design batteries to be larger than they need tobe to compensate for anticipated degradation as they age. As much astwo-thirds of the matrix 51 within a battery cell accounts fordegradation over the life of the battery. Therefore by using AGT eachbattery can be designed at one-third of its original size and weight,and yet provide the same energy characteristics. This enables three timeas much energy to be generated out of a battery of a given size. As thebattery ages it does not lose energy storage capacity because AGT keepsthe electrodes and the electrolyte in a ‘as new’ condition.

There are other factors that make current battery designs less thandesirable. The energy required to charge a battery is always greaterthan the energy it supplies. Thus, batteries are very inefficient. Whilethe battery discharges, chemical energy is converted to electricalenergy. During the charge process, electrical energy is converted tochemical energy by reversing the chemical reaction. This requireshigher-than-normal operating voltages to drive this chemical reaction inthe reverse direction. As noted in the background of the invention, thishigher voltage has two adverse effects. The first is that highervoltages cause gassing. Gassing occurs because when a cell is dischargeda majority of the electrolyte left is water (H₂O). When H₂O experiencesa potential it will separate into its constituents (electrolysis),hydrogen and oxygen. As the potential increases so will the gassing. Theeffects of flammable gases being formed in a sealed container areobvious. The construction of a battery must take this intoconsideration. A battery must be constructed in such a way that it hasthe ability to relieve this generated gas. AGT allows the reversechemical reaction to occur without using large voltage and currents.Therefore less gas is formed. Another, not so obvious, effect is thatthis formation of gas also takes away from the life of the battery.These gasses have no reason to go back into solution. This equates to aloss of water and therefore electrolyte. If the battery is a sealedunit, adding more water is not an option. Even though gas formation isundesirable it does cause mixing of the electrolyte within the cells.This has the advantage of minimizing stratification that can occur insome battery designs. Stratification occurs when certain levels of theelectrolyte become more reactive than others because of gravity. Thesecond adverse effect of higher voltage is that these additionalchemical reactions generate heat. Since the charge process is sotime-consuming this heat addition can become a limiting factor duringthe charge, and can cause structural damage.

Most approaches to enhancing battery life and energy storage capacityfocus on chemical means. AGT, however, is based on a mechanical, not achemical approach. In essence, it stirs up the environment so that thosestubborn PbSO₄ formations have no opportunity to form in the firstplace, and the SO₄'s have no choice but to go back into solution whenthe battery is recharged.

This new technology can be added during the manufacturing stage to anyrechargeable battery exhibiting the problems mentioned above. Thedimensions of the battery need not change. This technology can take manydifferent forms within the battery. In some embodiment, this technologyis added to the electrode grid. This addition will eliminate, and orminimize, all of the adverse effects mentioned above. The method bywhich this technology is incorporated into the electrodes may varygreatly. Regardless of the method of implementation, this technologywill surely revolutionize batteries as we know them. This technology isbased on mechanically exciting chemical reaction products within theenergy storage device 10 at energy levels proximate which covalent bondswith a matrix 51 of the energy storage device 10 would form absentexcitation. It employs an active material 31 mechanically-responsive toelectromagnetic signals, such as, but not limited to, PZT.

It is also possible to retrofit a battery which has already beenmanufactured. In such a retrofitted embodiment, the end-user or themanufacturer merely adds an active material 31 to the terminals of thebattery, driven by a control module. A majority of the electrode withina battery is made of a rigid type material. This rigid type material isused to telegraph the vibrations to the matrix 51. This latter method ofexciting the matrix 51 requires more energy due the larger amplitudevibrations that are required to over-come the mechanical lossesassociated with the electrodes. For a top post type lead acid batterythe actuators are manufactured to adhere to the post. They are of atubular design and slip right over the terminal. Regardless of themethod used to transmit vibrations to the matrix 51 the battery willbenefit from AGT.

In one embodiment shown in FIG. 3, an active material 31 comprising alead zirconate titanate (PZT) strip film substrate, or comparablematerial is housed within a protective material coating 32 which willnot react chemically within the cell. The film substrate is very thin;several layers of PZT sheet 33 may be required. Note that the thicknessof the PZT strip is preferably on the order of microns, and thethickness of the PZT sheet 33 is preferably on the order of mils. Alsoillustrated in FIG. 3 are internal leads 34 and connectors 35.

The protective coating 32 for the PZT strip film substrate preferablycomprises an acrylic, plastic or polyurethane material. This material isthick enough to house this active material 31, yet thin enough to ensurethat its vibrations are felt by the matrix 51. This coating material 32provides electrical and chemical isolation from the matrix 51,electrolyte and battery terminals. It is also capable of transferringheat away from the PZT strip. It allows disturbances to be feltthroughout the matrix 51. By a suitable choice of material, theprotective material itself can increase the strength of the electrode.This allows manufacturers to concentrate on increasing the energystorage capacity of the battery rather than improving strength. Batterycells are currently designed to withstand external vibrations. With theuse of AGT this design can shift to that of maximizing the energystorage efficiency of the battery. The film substrate forms strips, orother suitable arrangement, and is positioned so that when it vibratesit maintains (during discharge) or upsets (during recharge) the ionicbonds formed between the matrix 51 (e.g., Pb) and the chemical reactionproducts (e.g., SO₄). Leads 34 are attached internally to the actuationstrips and allow a control module to be connected 35 externally. Thebonds in the matrix 51 itself are much stronger, and if not will be madestronger. Several methods are available to strengthen bonds within thematrix 51. The matrix 51 itself can be doped with certain strengtheningelements to increase the strength of the bonds within it.

In addition, or alternatively, a PZT crystal could be added to a rigidstructure, in a predetermined position, to obtain the modal deflectionsdesired on the surface. The dimensions of this rigid structure may alsobe determined based on enhancing the frequencies of interest. It is wellknown, for example, that the resonant frequency of a PbSO₄ crystal(lowest energy band) is at approximately 3.26 MHz. The higher energylevels associated with the PbSO₄ covalent and ionic bonds are resonantat higher frequencies. Benefits associated with AGT are achieved withdriving signals in the frequency range from >400 KHz to 100 MHz. Thefrequencies at which the covalent bonds of interest will exist areapproximately between 1 MHz and 10 MHz and excitations at thesefrequencies may be achieved many different ways. Actuators can bepositioned to set-up standing waves that will stimulate the frequencyrange of interest. The driving signal need not be at and/or comprised offrequencies within the frequency range of interest. By scientificallydetermining various actuator configurations with the aid of computeranalysis programs, such as NASTRAN®, AGT will set-up standing waves thatwill be sub-harmonics and/or harmonics of the driving signal. But themain goal is mechanically exciting chemical reaction products within theenergy storage device 10 at energy levels proximate which covalent bondswith a matrix 51 of the energy storage device 10 would form absentexcitation, irrespective of the driving frequencies which may be used toachieve this.

In some embodiments, AGT produces vibrations that sweep through theselower level energy states throughout the discharge cycle. During thecharge cycle this range of frequencies swept thorough is extended toinclude the resonant frequency of highest energy PbSO₄ bond. FIG. 4illustrates the design approach in the illustrative situation where PZTmaterial is used to introduce these vibrations.

As shown the PZT material is operated over a linear range. The lowestfrequency f_(m) is the frequency at which the PZT has minimaldisplacement (z). The highest frequency f_(h) is the frequency at whichthe PZT material undergoes maximum displacement. During the discharge(d) cycle 41 the AGT control module sweeps through a frequency bandbetween f_(d1) and f_(d2). During the charge (c) cycle 42 the frequencyband is increased to a range between f_(d1) and f_(c1). The dimensionsof the vibrating plate is predetermined to maximize the responsesuitable for AGT.

This is illustrative of a number of important concepts. As notedearlier, mechanical excitations are preferably introduced during atleast part of a time while the energy storage device 10 is discharged.Further, they are preferably introduced during at least part of a timewhile the energy storage device 10 is charged. During discharge, it ispreferred to introduce the mechanical excitations at energy levelssubstantially maintaining the ionic bonds between the chemical reactionproducts and the matrix 51. During charge, it is preferred to introducethe mechanical excitations at energy levels substantially breaking theionic bonds between the chemical reaction products and the matrix 51 andcausing the chemical reaction products to return to an electrolyte ofthe energy storage device 10. This accounts for the fact that f_(c1) isillustrated to be higher than f_(d2) in FIG. 4. In some embodiments, itis preferred to sweep the mechanical excitations through a plurality ofenergy levels proximate energy levels of the covalent bonds.Particularly, it is preferred to sweep the mechanical excitations,during at least part of a time while the energy storage device 10 isdischarged, through a discharge cycle plurality of energy levelsproximate energy levels of the covalent bonds; sweep the mechanicalexcitations, during at least part of a time while the energy storagedevice 10 is charged, through a charge cycle plurality of energy levelsproximate energy levels of the covalent bonds; and sweeping the chargecycle plurality of energy levels through at least one energy levelhigher than a highest energy level of the discharge cycle plurality ofenergy levels. Finally, this illustrates the desirability ofmechanically exciting the chemical reaction products to an energy levelproximate a lowest-energy level of the covalent bonds, and also, ofmechanically exciting the chemical reaction products to an energy levelproximate a higher-energy level of the covalent bonds.

Again, while lead zirconate titanate (PZT) is used here to illustrativethe invention, it is but one example of an active material 31 that wouldbe suitable for use in connection with the invention, and is in no wayintended to limit the invention. Other examples of materials that wouldbe suitable for use in this invention include, but are not limited to,ferroelectrics, electrostrictive, ands magnetostrictive. Morefundamentally, any material presently known in the art or which may inthe future become known in the art will be suitable for use in thisinvention, providing that material has the ability to producedisplacement in the frequency range mentioned above with an externalexcitation, and in particular, for sufficiently exciting sulfatemolecules (and chemical reaction products generally) within an energystorage device 10 to an energy level such that electrons in the outervalence band of the sulfate molecules are excited to at least the nexthigher valence band of the sulfate molecules, thereby substantiallypreventing covalent bonds from forming between the sulfate molecules andthe matrix 51 of the energy storage device 10 and enabling the chemicalreaction products (e.g., sulfate molecules) to maintain a substantiallyunbound ionic state.

These small amplitude vibrations set up disturbances during dischargethat cause the PbSO₄ bonds to remain at their highest state. Thesedisturbances do not, however, drive the SO₄ ions away from the matrix 51because they are still subject to the chemical attractive forces(ionic). Then, during charge, the SO₄ ions are driven back into theelectrolyte during a time when their ionic bonds with the matrix 51 arenot necessary. One thus achieves the best of both worlds.

The active electrode, as shown in the embodiment of FIG. 5, is capableof handling a larger amount of current than its predecessors. We referagain to the lead-acid example. By pressing a grid on each side of thePZT sheet 33 comprising the active material 31 such as PZT strip filmsubstrate and PZT sheet 32, (explained below), the same amount of Pb orPbO₂ matrix 51 can be pasted on during the manufacturing stage. Therigid structure that the paste adheres to is the PZT sheet 32 itself.The method of adhering the paste to the sheet is with the use of a Pballoy grid lattice 52, which can take many forms, which penetrates theprotective coating itself. The protective coating will take the place ofgrids currently used. The thickness of the electrode is comparable tothat of current grids used in Pb-acid batteries. The Pb Alloy gridlattice 52 may be pressed on to the PZT sheet 32 and mounted. Thethickness of the matrix 51 on each side of the PZT sheet can be lessthan its predecessors—preferably about one-half the size of currentmatrix designs. Until AGT there was no reason to reconfigure anelectrode to include a non-chemically reactive material. This processwould only take away from the energy storage capacity of the battery. Inaddition, it would also limit the chemical reaction sites within thematrix 51 which reduce its current carrying capacity. The electrode isnow designed to enhance the (Pb and SO₄ covalent bonding) frequenciesdesired to make AGT more beneficial. It maximizes the vibrations ofinterest to affect more PbSO₄ chains within the pores of the matrix 51.In addition, the electrolyte does not have any difficulty in reachingthese chains. Therefore, for the same size battery, the energy storagecapacity is larger. This increase in energy density will bring thelead-acid battery back to the front lines within the “hybrid” and“electric” markets. Also illustrated as a shaded “cloud” are PbSO₄formations 53 on the matrix 51 surface.

With Active-Grid Technology, the battery can be recharged at any chargestate. All the SO₄'s go back into solution during every charge, everytime. Since there is no sulfation, shedding or gassing there is noreason why the battery should not last a lifetime. The following AGTcharge and discharge model, illustrated in FIG. 6, will be used toexplain the AGT process.

FIG. 6 demonstrates how AGT functions to manipulate the chargeacceptance of a battery cell 61. The concept of changing the way a leadacid battery accepts a charge is not new in itself. Currently themethods used are based on enhancing the chemical make-up of the battery.AGT does not alter the chemical make-up nor the chemical reactions goingon within a battery cell. The oxidation and reduction process is notchanged in any way. The cell still transfers the same amount ofelectrons during the charge and discharge cycle. In the model of FIG. 6,the battery cell 61 is represented by parallel plates (CB) with internalresistance (RB). The plates shown have two structures between the plateswhich represent PZT sheets with the matrix 51 attached 5. The modelshown is a fully charged battery which just started its discharge cycle.The AGT Control Module 62 is powered by the battery voltage and is usedto drive the actuators within the PZT sheet 33. In the illustrateddynamic PZT model 63, the mechanical resonance of the PZT device isrepresented by L1, C1 and R1. Since it is a dielectric with electrodesit also has an electrical capacitance C2. This is a simplified model ofthe PZT device. Many forms of dynamic models are available for the PZTstructures. The charge unit 64 can be any type of DC source such as analternator in a car. The DC loads 65 are components such as motors,radios, fans etc. The switches 66 are currently shown in the dischargingstate. When a charge is applied the AGT Control Module (101 in FIG. 10)switches each switch to the charging position.

As now illustrated in FIG. 7, during the discharge phase the batterydischarges through RB, the DC loads and the AGT control module. Theinternal resistance of the battery is very small and compared to the DCload resistance the AGT control module resistance is very large. Thecontrol module does not draw a lot of power during the discharge phase.The amount of power drawn is comparable to the DC loads the battery issupplying. As the cells discharge, precipitates, e.g., PbSO₄'s formthroughout and on the surface of the matrix 51. During this phase theAGT control module generates signals that drive the PZT actuators withinthe PZT sheet. The frequencies generated sweep through the resonantfrequencies of the lower-energy PbSO₄ covalent bonds, and of the ionicbonds.

Continuing with the lead-acid example, as shown by the chemical reactionproduct “cloud” 71, the SO₄ ions collect on the plates in a randomorder. They chemically react with the Pb and PbO₂ matrix 51. The PZTsheet is vibrating while the battery discharges which keeps the PbSO₄bonds in their highest energy (ionic) states. The PbSO₄'s thus no longerplate out on the matrix 51. Instead they form a compacted cloud 71 ofvery soft sludge type material. The pattern of distribution is dependenton the driving signal and the PZT sheet structure. As the batterydischarges its terminal voltage decreases. The AGT control module isconfigured such that based on a predetermined condition (e.g., voltagelevel), the charge cycle starts. With AGT there is no longer a concernfor the amount of discharge prior to charging; that is, the battery doesnot have to be fully discharged periodically to restore optimumefficiency. AGT will allow the battery to be charged at any time duringthe discharge cycle without fear of battery degradation due tosulfation.

FIG. 8 now illustrates the charge cycle. When the charge cycle is calledfor the DC load switch opens, the charging switch shuts and an AGTcontrol module switch shuts (these switches are generally referenced by66 and they are controlled by control module 101). The AGT controlmodule activates the PZT or similar active material 31 to extend therange of frequencies swept through, as discussed earlier in connectionwith FIG. 4. This added range includes the resonance frequency of thehighest-energy PbSO₄ ionic bonds. As noted above and illustrated by theexpanded cloud 81 in the vicinity of the CB plates, the PbSO₄ bondsdisintegrate and the SO₄is driven back into the electrolyte.

It is known throughout the industry that batteries exhibit capacitiveeffects. These capacitive effects are what AGT is focused on. A batterycomprises plates and they are separated by a medium. The medium is theelectrolyte and the PbSO₄ formation on the plates. In capacitor theorythe dielectric between the plates is characterized by its electricalpermittivity.

AGT also uses this relationship to describe the charging characteristicsof a battery. In a dielectric the permittivity is dependent onfrequency. This can be seen by the dependence of capacitive reactance onfrequency. AGT manipulates the permittivity of the electrolyte and PbSO₄formations by disturbing the formations with frequencies they aresusceptible to. In turn, AGT has gained control of the electricalresponse characteristics of the battery. During the discharge phase thebonds are kept excited hence setting the storage device up for itscharge phase. When the charge is applied the permittivity will be suchthat it offers less impedance to the charging source.

In one embodiment, the actual electrode grids themselves can be designedto incorporate and active material 31 mechanically-responsive toelectromagnetic signals, such as PZT. Battery manufacturers often findthemselves trying to explain why batteries fail early in life. In thepast, they have claimed that the inherent piezoelectric effect withinthe battery cell actually causes the battery to fail early. Active-GridTechnology will not settle for this explanation—but it will exploit sucheffect by purposely introducing mechanical excitations at energy levelsproximate which covalent bonds with a matrix 51 of the energy storagedevice 10 would form absent excitation.

In particular, if the plates have a piezoelectric effect then there issome expansion and contraction during charge and discharge and this maybe causing batteries to fail early, sometimes catastrophically. Oneembodiment of AGT enhances (dopes) the electrodes to produce mechanicalexcitation around the frequencies of interest, frequencies at energylevels for which detrimental covalent bonds want to exist. Thus, thisbuilt-in piezoelectric effect can be exploited by an external means.This will require intentionally adding the correct proportions ofzirconate and titanate (in the case of PZT), or their counter-parts, tothe paste prior to its application to the grid lattice 52.

Researchers have demonstrated that batteries exhibit mechanicalresonance which is a function of their structural design. Others havebeen trying to exploit this behavior to enhance shaking the sulfatecrystals back into solution. Manufacturers, on the other hand, designbatteries according to its operating platform. They are concerned withsuppressing the mechanical instabilities rather then cultivating them.For instance, a car battery is designed to withstand vibrations on theorder of 10-300 Hz because this is what an ordinary car would besubjected to on an average road. Undoubtedly, manufacturers takemeasures to ensure the cell can withstand continued sustained vibrationsin this range, since several vibrational performance/endurance test mustbe passed prior to use in the industry.

AGT can take advantage of the piezoelectric effect inherent in theelectrode paste. Active elements can be added to the paste to enhanceits electromechanical response to frequencies at which theelectrochemical performance can be altered. These active elements can beadded to the pre-existing chemical make-up of the electrode that willnot alter the electrical response characteristics of the cell withoutsome type of external excitation when can be subjected to control.

Instead of using large voltages and huge currents to dislodge thestubborn SO₄'s during the charging process as disclosed in the priorart—which itself causes damage to the battery—these SO₄'s will alreadybe in the excited state because of mechanical excitations applied duringdischarge, and be dislodged mechanically, with a further impetus toremoval from the DC charging itself. These disturbances are large enoughto upset the PbSO₄ bonds but small enough not to upset the internalbonds of the matrix 51 itself. When a charging excitation is applied tothe active grid it actuates the vibration devices within the matrix 51.The PZT driving signal is of a predetermined amplitude, shape andfrequency to enhance the process. Most importantly, chemical reactionproducts within the energy storage device 10 at energy levels proximatewhich covalent bonds with a matrix 51 of the energy storage device 10would form absent excitation, thereby substantially maintaining ionicbonding between the chemical reaction products and the matrix 51 andsubstantially preventing the chemical reaction products from covalentlybonding with the matrix 51. The PbSO₄ bonds that build up in the poresof the matrix 51 disassociate with the aid of these mechanicalexcitations. The SO₄'s are forced into the electrolyte, and the timerequired to complete the charge is dramatically decreased. Highervoltages are not required to drive the SO₄'s into solution since theyare assisted by a very-low-power-consuming device, namely, the activematerial 31. Therefore, gassing and heat generation—both of which damagethe battery—are eliminated. Additionally, small amplitude disturbancesset up in each active grid assembly via the control module minimizestratification.

The PZT, or equivalent active material 31 for introducing mechanicalexcitations, draws minimal current and may be modeled as a capacitor.Large voltages producing huge currents to drive the SO4's back intosolution are no longer needed. The current charging systems will nolonger have to supply large currents and can be reduced in sizeaccordingly. Therefore, it is possible, for example, that instead of a130 Amp alternator, a 30 Amp alternator will do the job.

This reduction in size and increased energy density will be useful inthe automobile industry. In addition, no matter what the temperature,the user will enjoy full cold cranking amps every time. It isstraightforward to use AGT for providing electrical power from saidenergy storage device 10 to a motor vehicle; and receiving electricalpower into said energy storage device 10 from said motor vehicle.

Benefits will also be seen in the “hybrid” industry; the decreasedcharging time and increased efficiency will undeniably make runningelectric automobiles, trains, buses, and boats more appealing. In thissituation, AGT may be used for powering a load using hybridized energyfrom a supplemental source of energy in addition to energy from saidenergy storage device 10, in varying proportions responsive to varyingoperating conditions.

The ‘home battery system’ is a great idea; unfortunately, it is a richman's toy. If you lose power you simply switch over to reserve capacityto keep your home functioning. If you lose power when your battery packhas had time to charge up, which takes approximately 5 to 7 hours, itworks well. The most expensive part of this system is the equipment usedto ramp up the power supplied by the grid. The advantage of being ableto charge the battery pack at the voltages supplied by the grid isobvious. Active-Grid Technology will give this market the boost it hasbeen looking for. Instead of waiting for power interruptions, one cancontinuously switch back and forth between power supplies. If the powergrid is overloaded and expensive, one can simply switch over to batterypower without worrying about the recharge time, as it will take muchless time with AGT. At present, a major limitation of power generationand distribution systems is that power must be generated in real time,transmitted over the grid, and then used The ability to store largequantities of power made possible by AGT changes the situationdramatically, greatly enhancing the ability of the power grid to avoidblackouts, and providing emergency power whenever it is needed. In thissituation, which has worldwide energy implications, AGT may be used forreceiving electrical power into said energy storage device 10 from apower generation and distribution system; supplying electrical powerfrom said energy storage device 10 into said power generation anddistribution system; and load balancing said receiving and supplying ofelectrical power from and into said power generation and distributionsystem, in response to varying operating conditions.

AGT batteries are more compact, last longer, charge quicker and onlyrequire about as much power to re-charge as was expended because oftheir increased efficiency and their elimination of many sources ofenergy loss. The vibrations of the active grid elements are very smallin amplitude; they are not even noticeable to the user. This vibratingsurface does not cause interference with the adjacent plates because theactual displacement from the centerline of the grid is on the order ofmicrons. The vibrations are of sufficient amplitude and frequency todislodge the excited SO₄'s into solution. The remaining PbSO₄'s areunbonded and the SO₄'s returned to the electrolyte, and the speed of thereaction is greatly enhanced.

FIG. 9 is an exploded view of an active grid electrode element. On theleft is a completely discharged electrode grid element. On the right isthat same element during charge with an actuation applied to the activegrid. The matrix 51 is not shown and the PZT film substrates, within thePZT sheet, are shown as discrete elements for the purpose of clarity.Note the dense, ionically-bonded PbSO₄ cloud 71 on the left and theexpanded, more dispersed SO₄ cloud 81 on the right which includesunbonded SO₄'s which have been excited back into the electrolyte.

The actuation signal is specifically tailored to excite the unwantedbonds; it is designed to maximize the speed at which the chemicalreaction products, e.g., SO₄'s are dislodged. It is applied to theactuators externally by the control module 101 mounted directly on thebattery as shown in FIG. 10, or possibly within the battery (not shown).The active elements themselves can be made of any type of activematerial 31 or equivalent. The signal amplification required forActive-Grid Technology does not require an elaborate control system.During the discharge and charge process a waveform generated within thecontrol module is applied to the active grid 5 assemblies. This controlmodule, preferably, is powered by the battery during the discharge andby the charging system during the charge.

The Pb and PbO₂ grids are very soft. While the grid elements in sometypes of batteries are harder, improving stiffness of softer grids isthe focus of much research. That is why grid lattices are used withseparators that help to support the soft electrodes. A betteralternative for grid lattices is the use of a PZT sheet. In theembodiment of FIGS. 3 and 5, the actuators are within these sheets.There is an active vibrating film substrate everywhere the matrix 51 ispresent. The material used for the sheet is fairly rigid and does nottake part in any reactions. FIG. 10 is a drawing illustrating batteryitself with the active material 31. The electrolyte and separators arenot explicitly shown, but would be in regions such as designated by 102.As noted above, the appearance and relative physical dimensions of thebattery remain unaltered. As mentioned earlier, the absolute batterydimensions needed to obtain a given energy result are reduced. Thebattery posts 103 can also comprise the active material 31.

Active-Grid Technology is the next generation battery. The use of a PbOpaste to convert chemical energy to electrical energy is not new, butthe idea that this paste can be doped with certain substances, likezirconate and titanate, and then caused to mechanically oscillate toachieve this technology via the matrix 51 is novel and inventive. Thisis a battery which never sleeps. The plates are working continually tokeep the SO₄ ions in constant confusion. If these ions try to settle in,they are kicked out by the next vibration. Since chemical attraction isstronger than the mechanical energy, the electron transfer is unimpeded.Instead of painting the matrix 51 with SO₄ chains, the SO₄'s form acloud at a safe distance from the formation sites. When a reversepolarity is applied to recharge the battery, the cloud dissipates intothe electrolyte, and the battery is fully charged much more quickly.

Will this technology consume the power stored in the battery by keepingthe plates vibrating? This is a good question. Scientists understandthat one can achieve large forces with only a small amount of power.This is what makes this type of active material 31 so appealing. Theamount of power used to vibrate the plates at this microscopic level ison the order of 1-3% of the capacity of the battery. Indeed, duringexperimental testing of AGT, is was demonstrated that the average energyused to cause vibration was approximately 1% of the capacity of thecell. This is not much to give up to gain the benefits associated withAGT.

The lead-acid battery has staying power in the industry. New batteries,such as Ni—Cd, lithium, and Ni—Mh, have several advantages, but theyalso suffer disadvantages similar to those discussed above. With AGTtheir disadvantages can be eliminated. Regardless of the type of batterythis technology is applied to, the following benefits will be achieved:this technology will eliminate sulfation (and analogous effects in otherbatteries), shedding, memory, gassing, aging and freezing; it willreduce the charging time of a lead-acid battery from hours to minutesreduce stratification, allow a battery to be charged with voltagecomparable to its operating voltage, return the battery to a like-newcondition on every charge and increase the life of the battery; itreduces the amount of heat produced during the charge and reduces theamount of deformation within the cell; it increases the time the batterycan be operated under load and the load carrying capabilities of thebattery. All these things can be achieved without altering the physicaldimensions of the battery, and indeed, can be achieved in a smallerspace.

Indeed, if the frequencies are targeted correctly then the only bondthat will have to be broken during the charge is the ionic bond betweenthe SO4 ion and the matrix 51. By setting the cell up to accept chargeall the current chargers on the market will work much more efficiently.Presently, robust chargers are employed to jam the energy into the cellwithout the ability to effect the cell and make it more compatible withthe charger.

AGT will change the way we look at a battery. We already have ‘smart’phones, cards, missiles, skis, and rackets, now we will have a ‘smartbattery’. When the efforts of battery manufacturers turn to this newtechnology, many more possibilities will become apparent. AGT is notfocused on finding better chemicals to make batteries with; it isfocused on improving what we have. In an alternative embodiment, amagnetic field might be used to control little pieces of iron within thebattery electrolyte so that when excited they will form the activematerial 31 used to scrub the plates clean. As noted above, electrodepaste could be chemically doped so that when a charge is applied thepaste itself vibrates so the unwanted bonds are shaken away. Activematerials 31 can be suspended in the electrolyte or connectors 102. Theycan comprise part of the casting 105. The current used to actuate theactive materials 31 can be introduced in conventions ways (e.g., acrossthe battery potential) or in unconventional ways such as by magneticinduction techniques 104 such as those set forth in U.S. Pat. No.6,040,680. All these possibilities and many others will suggestthemselves once the battery experts shift their paradigm. In the future,reference to an active substance within a battery will require furtherclarification. Is it chemically active, or is it mechanically ‘active’?

Why hasn't AGT already been developed? First and foremost, batteryexperts have been improving on lead-acid battery technology for years.If they stumbled on a process that caused motion within a battery, theypromptly eliminated it. The practice of moving plates within a batterycell was not something they would see as desirable. When the push camefor a more energy-efficient battery technology, everyone looked towardsnew chemical reagents as the way to go, new and exciting technologiesthat will be around for a long time. Those manufacturers that continuedin lead-acid technology came up with the gel-cell, advanced lead-acidand valve regulated lead-acid (VRLA) batteries.

Materials science is a very new and exciting field. The possible gainsassociated with this science are endless. Smart labs across the worldare applying this science to just about everything under the sun. Theyhave turned houses into auditoriums by making speakers out of theirwindows, they have developed a ceramic material that lubricates itself,they have made helicopter rotors that bend on control, they have made alube oil that changes its viscosity with a magnetic field controlsignal, and they have made airplane wings that change their shape when acurrent is applied. There is no end to the applications of this science.AGT is the next logical step in applying this science to the battery.

PZT was chosen to illustrate AGT because it is convenient and is readilyavailable today. It is functioning around the world, and in space. Themajor limitation found in using this material is its user's inability tocontrol it. This material is susceptible to non-linear response if usedover a large range of input signals. In other words, if you apply asquare-wave electrical input signal you will not necessarily get asquare-wave response. Scientists and engineers are frantically pursuingmethods to model accurately, and thus control, this type of material.The major push in this science is in developing a material that has botha large displacement and that can be accurately controlled throughoutthis displacement. While great progress is being made in this area, AGTdoes not require large displacement, nor does it require elaboratecontrol systems; AGT uses this material the way it wants to be used—itjust vibrates it.

AGT is intentionally moving the internal parts of a battery from withinthe battery itself. AGT does not discriminate between batteries. Anybattery that uses chemical reagents can benefit from AGT. Any batteryrequiring external energy to drive the chemical reaction in the oppositedirection can benefit from AGT. This technology can be applied to alltypes of batteries, as elaborated earlier. As set forth above, AGT is apreventative maintenance system. It stops the build-up of chemicalreaction products, e.g., SO₄'s from collecting in a region where onedoes not want them, as opposed to trying to remove them once they arethere.

Battery manufacturers still have the choice of which battery technologyto follow. Recent advances in nickel-cadmium; nickel-metal-hydride,lithium-ion, lithium-polymer and high temperature sodium-sulfurbatteries are promising. Unfortunately, these battery technologies willsuffer growing pains. If one considers the fact that lead-acid batterieshave been around for 100 years, and are still being improved, these newtechnologies have a long way to go. AGT can improve all of them, old andnew.

Although much of the illustration herein is based on a battery, thedevices and method disclosed herein can be applied to a broad range ofenergy technologies, including solar energy cells.

In a preferred embodiment, the mechanical excitations introduced intothe energy storage device 10 via the active material 31 are periodicoscillations, that is, vibrations at a period oscillation frequency sucha sin wave oscillating over a domain of greater than 2π. This is to bedistinguished from a single, sharp rise time pulse followed by aquiescent period much greater than the rise time, such as employed inmany of the prior art patents discussed in the background of theinvention. It is less preferred, though still acceptable, tomechanically pulse the chemical reaction products with a pulse of apredetermined rise time.

It is to be understood that someone might wish to supplement themechanical excitations disclosed herein and the various method ofachieving them, with more conventional types of electrical stimulationsuch as but not limited to the types of electrical stimulation disclosedin the prior art. For example, one might engage in the steps ofelectrically exciting, in addition to said mechanically exciting, thechemical reaction products within the energy storage device 10 at saidenergy levels proximate which covalent bonds with the matrix 51 of theenergy storage device 10 would form absent excitation, thereby furthersubstantially maintaining ionic bonding between the chemical reactionproducts and further substantially preventing the chemical reactionproducts from forming covalent bonds with the matrix 51; and introducingthe electrical excitations into the energy storage device 10 via anelectric current comprising non-DC components, in addition to saidelectromagnetic signal. In a preferred embodiment of this approach, asmall-amplitude, AC ripple current is used to supplement the mechanicalexcitations, further preventing the chemical reaction products fromsettling down into covalent bonds with the matrix 51.

One might also engage in the steps of electrically exciting, in additionto mechanically exciting, the chemical reaction products within theenergy storage device 10 at energy levels suitable for substantiallybreaking the ionic bonds between the chemical reaction products and thematrix 51 and causing the chemical reaction products to substantiallyreturn to an electrolyte of the energy storage device 10, therebysubstantially breaking the ionic bonds between the chemical reactionproducts and the matrix 51 and causing the chemical reaction products tosubstantially return to an electrolyte of the energy storage device 10;and introducing the electrical excitations into the energy storagedevice 10 via an electric current comprising non-DC components, inaddition to said electromagnetic signal. This is particularly helpfulduring the charge cycle, where a current is already being pumped intothe energy storage device 10 in order to recharge it. Thus, for example,by overlaying a small AC ripple on the charging current, further impetusis provided to break the ionic bonds with the matrix 51 and drive thechemical reaction products back into the electrolyte. Because thechemical reaction products are already in an excited state because ofthe mechanical excitations state and have not been permitted to everform covalent bonds with the matrix 51, the energy required for thissmall AC ripple is much less than the energy that would be required tobreak covalent bonds had they been allowed to form in the first place.Therefore, the electrical stimulus does not need to be as strong and theadverse effects discussed earlier are more readily averted.

Thus, supplemental electrical stimulation can be mixed and matched withmechanical stimulation in various combinations. Mechanical stimulationcan be used to prevent covalent bonding in the first place duringdischarge, and electrical stimulation—requiring much less energy—can beemployed to drive the chemical reaction products back into electrolyteduring charge. More generally, the step of introducing said mechanicalexcitations may further comprise introducing said mechanical excitationsduring at least part of a time while the energy storage device 10 ischarged; and the step of introducing the electrical excitations mayfurther comprise introducing said non-DC components during at least partof a time while the energy storage device 10 is discharged. Or, viceversa, the step of introducing said mechanical excitations may furthercomprise introducing said mechanical excitations during at least part ofa time while the energy storage device 10 is discharged; and said stepof introducing the electrical excitations may further compriseintroducing said non-DC components during at least part of a time whilethe energy storage device 10 is charged.

The method and associated devices disclosed herein, of mechanicallyexciting chemical reaction products within the energy storage device 10at energy levels proximate which covalent bonds with a matrix 51 of theenergy storage device 10 would form absent excitation, therebysubstantially maintaining ionic bonding between the chemical reactionproducts and the matrix 51 and substantially preventing the chemicalreaction products from covalently bonding with the matrix 51; andintroducing the mechanical excitations into the energy storage device 10via an active material 31 mechanically-responsive to electromagneticsignals, in response to an electromagnetic signal; whereby: degradationis substantially prevented by substantially preventing the covalentbonds from forming and by exciting the energy storage device 10mechanically rather than via degrading electrical excitation; and energyperformance is improved by requiring lower amounts of energy forexciting the chemical reaction products via said active material 31 thanwould be required to similarly excite the chemical reaction productswithout said active material 31, and by substantially preventing thecovalent bonds from forming and causing degradation, is clearly noveland nonobvious over all of the prior art discussed in the background ofthe invention.

So too, the method and associated devices disclosed herein, ofmechanically exciting an energy storage device 10 at frequenciesproximate resonant frequencies at which covalent bonds between chemicalreaction products within and a matrix 51 of the energy storage device 10would form absent excitation; and introducing the mechanical excitationsinto the energy storage device 10 via an active material 31mechanically-responsive to electromagnetic signals, in response to anelectromagnetic signal, is clearly novel and nonobvious over all of theprior art discussed in the background of the invention. We now turn toexamine some of the benefits of the devices and methods disclosedherein, in relation to the prior art.

Mechanical excitations as disclosed herein, are clearly preferable toelectrical excitations, because as noted earlier, electrical excitationsdegrade the energy storage device 10 by attacking the structuralelements of that device, and because a fair amount of energy is requiredto create electrical excitations strong enough to remove sulfates andsimilar deposits once they are already bonded to the matrix 51. If moreenergy is used to prevent sulfation-like effects than is saved bypreventing these effects in the first place, the net result is an energyloss and this is part of the problem with much of the prior art thatemploys electrical stimulation. If sharp pulses rather than gentle,periodic oscillations are used as disclosed in the prior art, thissledgehammer effect is very damaging to the energy storage device 10structure. If energy levels below the covalent bonding energies areemployed, the results are simply much less effective. If after-the-factremoval of sulfates is the goal—as it is in the prior art—then much ofthe damage is already done, and the energy needed to undo the damage—aswell as the damage cause by removal itself—is sharply increased. As withmany things, preventing the chemical reaction products from covalentlybonding with the matrix 51 is far preferable to removing the chemicalreaction products after they are already bonded.

The considerations that underlie the prior art when using electricalstimulation do not carry over in an obvious way to situations wheremechanical stimulation is applied. That is, one cannot simply say: let'stake whatever is done electrically, and mimic it mechanically instead.The prior art itself makes this clear. While the speed of anelectromagnetic wave or an oscillating current can be regarded as“instantaneous” with respect to the physical structure and dimensions ofthe energy storage device 10, the speed of a mechanical vibration—whichis effectively a sound wave albeit at ultrasonic frequency—is muchslower. The speed of mechanical vibration is, of course, the speed ofsound through the transmission medium. As a result, the dynamics ofpropagation are—and are perceived by the prior art to be—quite differentthan in the electrical case. This is what has led the mechanically-basedprior art to teach that the choice of frequency ought to be determinedby the physical structural characteristics of the energy storage device10, with frequency of excitation varying inversely with physicaldimensions. This approach teaches directly away from mechanicallyexciting chemical reaction products within the energy storage device 10at energy levels proximate which covalent bonds with a matrix 51 of theenergy storage device 10 would form absent excitation, as is disclosedand claimed herein, irrespective of the physical characteristics of theenergy storage device 10.

Additionally, with the electrical approaches, one would not be inclinedto take DC power from the energy storage device 10 while it isdischarging, convert it to high-frequency AC, and then pump it back intothe energy storage device 10 to keep the chemical reaction products fromforming covalent bonds with the matrix 51. There is simply too muchenergy required to do this. On the other hand, a small amount of theenergy storage device 10 energy could be used to vibrate an activematerial 31, with much higher effectiveness and much less energy usage.Thus, it becomes highly practical with mechanical approaches to addresssulfation-type effects during the discharge cycle, rather than wait forthe charge cycle when a charger is available to pump in high energypulses to dislodge deposits. And, because it is much more feasible withmechanical approaches to stir up the chemicals during the discharge inaddition to the charge cycle, prevention is facilitated overremediation, and “blasting” the deposits is replaced with gently coaxingthe deposits, with no ill effects on the energy storage device 10. Thecontrast between what is feasible with electrical stimulation and whatis feasible with mechanical stimulation is analogous to removing icefrom a frozen surface at 0° F. with an ice pick which also damages thesurface and requires a great deal of energy, or maintaining the ice nearphase change proximate 32° F. and then sweeping away the loose slushwith a broom that easily clears the surface without damage. So, once amechanical approach is selected, the process as a whole must beapproached differently, and what is known from electrical approachessimply does not carry over in an obvious manner to mechanicalapproaches.

Using mechanical excitation, the present disclosure teaches how toselect the optimum frequency or frequencies of mechanical excitation, inorder to optimize the energy efficiency of the energy storage device 10and avoid degradation. That is, the central question is: for mechanicalstimulation of energy storage devices, what frequencies should be used,and on what basis are these frequencies selected? The prior art teachesthat mechanical stimulation frequencies are to be selected withreference to the physical characteristics of the energy storage device10, including the size of the electrode elements, which leads towardsub-MHz frequencies in most instances other than for very smallelectrodes or electrode elements. This disclosure, in sharp contrast,teaches that the physical properties of the batteries do not matter andthat the selection of mechanical frequencies are invariant with respectto the physical characteristics of the energy storage device 10. Rather,the frequencies are to be chosen with reference to the energy levelsproximate which covalent bonds with a matrix 51 of the energy storagedevice 10 would form absent excitation.

From this, many further consequences can be deduced. First, thisdisclosure teaches how to improve energy storage device 10 performancenot just for a single type of energy storage device 10, but for alltypes of chemical-to-energy energy storage device 10. This is becausethe key starting point in all cases, are the covalent bonding energies.There is no one “correct” frequency, because different energy storagedevice 10 types will exhibit undesired covalent bonding at differentenergies which are based on the chemical nature of their constituents,not their physical, dimensional characteristics as taught in the priorart. Based on this, the recipe for choosing frequencies in any givensituation is clear, even for chemical-to-electrical energy storagedevices not yet known today, or for energy storage devices employingelectrode and electrolyte materials which are not yet known today.

Second, this disclosure teaches that the goal is twofold: duringdischarge, to maintain ionic bonds between the chemical reactionproducts and the matrix 51, because these are necessary to produceenergy, and during charge, to break the ionic bonds and drive thechemical reaction product back into the electrolyte thereby returningthe energy storage device 10 into an “as new” state. Here too, once thisrecipe is laid out, the selection of frequencies follows from anunderstanding of the chemical constituents and their various covalentand ionic bonding energies. During discharge, the frequencies are chosento keep covalent bonds from forming at the various energy levels wherethey would otherwise be prone to form. During charge, preferably, thefrequencies are further ramped up to break the ionic bonds and drive thechemical reaction products back into the electrolyte. In addition tobreaking the ionic bonds, the mere physical vibration itself also shakesup the whole energy storage device so that the chemical reactionproducts mix back onto the electrolyte and restore the device into its“as new” state.

As a consequence of all of the foregoing, degradation is substantiallyprevented by substantially preventing the covalent bonds from formingand by exciting the energy storage device 10 mechanically rather thanvia degrading electrical excitation; and energy performance is improvedby requiring lower amounts of energy for exciting the chemical reactionproducts via said active material 31 than would be required to similarlyexcite the chemical reaction products without said active material 31,and by substantially preventing the covalent bonds from forming andcausing degradation.

Once this sort of approach is known, then the electrical stimulusapproaches take on a new light, and they can be used in smaller “doses”to supplement the mechanical approaches disclosed here without damage tothe energy storage device 10 structure, as discussed earlier in thisdisclosure.

While only certain preferred features of the invention have beenillustrated and described, many modifications, changes and substitutionswill occur to those skilled in the art. It is, therefore, to beunderstood that the appended claims are intended to cover all suchmodifications and changes as fall within the true spirit of theinvention.

1. A method for improving energy performance and substantiallypreventing degradation of a chemical-to-electrical energy conversionprocess of an energy storage device (10), comprising the steps of:mechanically exciting an energy storage device (10) at frequenciesproximate resonant frequencies at which chemical covalent bonds betweenchemical reaction products and a matrix (51) of the energy storagedevice (10) would form absent excitation; and introducing the mechanicalexcitations into the energy storage device (10) via an active material(31) mechanically-responsive to electromagnetic signals, in response toan electromagnetic signal.
 2. The method of claim 1, said step ofintroducing said mechanical excitations further comprising: introducingsaid mechanical excitations during at least part of a time while theenergy storage device (10) is discharged; introducing said mechanicalexcitations during at least part of the time while the energy storagedevice (10) is discharged at said frequencies proximate said resonantfrequencies; introducing said mechanical excitations during at leastpart of a time while the energy storage device (10) is charged; andintroducing said mechanical excitations during at least part of the timewhile the energy storage device (10) is charged at at least onefrequency higher than said resonant frequencies; the energy storagedevice (10) comprising a lead-acid battery; and said step ofmechanically exciting further comprising mechanically exciting thechemical reaction products at frequencies comprising approximately 3.26MHz.
 3. The method of claim 1, further comprising the step of: doping atleast one electrode of said matrix (51) with a doping materialcomprising said active material (31).
 4. The method of claim 1, furthercomprising the step of: providing said active material (31) inmechanical connection with at least one electrode of said matrix (51).5. The method of claim 1, further comprising the step of: providing anelectrolyte of the energy storage device (10) comprising said activematerial (31).
 6. The method of claim 1, further comprising the step of:providing a separator of the energy storage device (10) comprising saidactive material (31).
 7. The method of claim 1, further comprising thestep of: providing a casting of the energy storage device (10)comprising said active material (31).
 8. The method of claim 1, furthercomprising the step of: providing said active material (31) inmechanical connection with at least one terminal of the energy storagedevice (10).
 9. The method of claim 1: said active material (31)comprising magneto-responsive material responsive to magnetic fields;and said electromagnetic signal comprising a magnetic field; said stepof introducing said mechanical excitations further comprising:introducing said mechanical excitations via said magneto-responsivematerial, in response to said magnetic field.
 10. The method of claim 1,further comprising the steps of: electrically exciting, in addition tosaid mechanically exciting, the energy storage device (10) atfrequencies proximate said resonant frequencies; and introducing theelectrical excitations into the energy storage device (10) via anelectric current comprising non-DC components, in addition to saidelectromagnetic signal.
 11. An energy storage device (10) whichsubstantially improves energy performance and prevents degradation ofits chemical-to-electrical energy conversion process, comprising: anactive material (31) mechanically-responsive to electromagnetic signalsfor introducing mechanical excitations into the energy storage device(10) in response to an electromagnetic signal, at frequencies proximateresonant frequencies at which covalent bonds between chemical reactionproducts and a matrix (51) material of the energy storage device (10)would form absent excitation.
 12. The device of claim 11, saidmechanical excitations comprising: mechanical vibrations vibrating thechemical reaction products at a predetermined periodic oscillationfrequency.
 13. The device of claim 11, said mechanical excitationscomprising: mechanical pulses pulsing the chemical reaction productswith a pulse of a predetermined rise time.
 14. The device of claim 11:the matrix (51) comprising lead (Pb); the chemical reaction productscomprising sulfate (SO₄); and the covalent bonds comprising lead sulfate(PbSO₄) covalent bonds; said mechanical excitations comprising afrequency of approximately 3.26 MHz.
 15. The device of claim 11, furthercomprising: a control module causing said mechanical excitations, duringat least part of a time while the energy storage device (10) isdischarged, to be introduced at said frequencies proximate said resonantfrequencies; and said control module causing said mechanicalexcitations, during at least part of a time while the energy storagedevice (10) is charged, to be introduced at to be introduced at at leastone frequency higher than said resonant frequencies.
 16. The device ofclaim 11, further comprising: said active material (31) external to andin mechanical connection with the energy storage device (10).
 17. Thedevice of claim 11, further comprising: an electric current comprisingnon-DC components, in addition to said electromagnetic signal;electrical excitations, in addition to said mechanical excitations,introduced into the energy storage device (10) via said non-DCcomponents, at frequencies proximate said resonant frequencies; acontrol module causing said mechanical excitations to be introducedduring at least part of a time while the energy storage device (10) ischarged; and said control module causing said non-DC components to beapplied across the electrical potential during at least part of a timewhile the energy storage device (10) is discharged; wherein: said non-DCcomponents are introduced into the energy storage device (10) by beingapplied across an electrical potential of the energy storage device(10).
 18. The device of claim 11, further comprising: electrical powerfrom said energy storage device (10) provided to a motor vehicle; andelectrical power received into said energy storage device (10) from saidmotor vehicle.
 19. The device of claim 11, further comprising: ahybridizer causing energy from a supplemental source of energy inaddition to energy from said energy storage device (10), in varyingproportions responsive to varying operating conditions, to power a load.20. The device of claim 11, further comprising: an electrical connectionbetween said energy storage device (10) and a power generation anddistribution system enabling said energy storage device (10) to receiveelectrical power from said power generation and distribution system;said electrical connection further enabling said energy storage device(10) to supply electrical power into said power generation anddistribution system; and a load balancer causing said energy storagedevice (10) to receive and supply said electrical power from and intosaid power generation and distribution system, in response to varyingoperating conditions.